92 hurley smavidison redo

[rabies]

Hi....bought a bike cheap. progress might as well land here
1992 xlh.

when i got it. looked nice. kinda ran....ignition needed help.

got it home.
ignition was melted...

[rabies]

found lots and lots of issues after trying to address the ignition.
bought dynatek stuff waiting on the advance curve thingy to come in the mail.


bought a few doo dads




my *easy install* of the TC Bros mid controls (pretty nice btw)
i had to remove the exhaust and i broke a stud....the hardest to reach one *DEEP FN BREATH*
tried to weld a nut on. nope. 3 tries. nope.




to drill it out. i had to remove chain. left side controls. all mounts. your sister. just to slide it over enough to drill straight.

[rabies]

heres my favorite part..................
so to take off the turn signals and wiring...i remove the control buttons....stripped bolts. had to drill out.
onto medusa.

she got a haircut


made a leather timing cover.


here she sits.


waiting on alot of parts. every bolt had to get drilled/heated/vice gripped/spit on.

[rabies]

got bored waiting for parts.
so the davinchi in me came out.




also having super loads of fun.....

[rabies]

making my own harness.
I have to install new chain.
find a rear fender....because i smashed the old one....
https://www.youtube.com/watch?v=q2QPYB6Asp8

also some hardware to replace stuff broken/stripped/snapped

[rabies]

fancy o-ring chain. aparantly bike came with the chain conversion.


LED headlight mounted in and ground.
along with ugly front fender



made leather grips



waiting on coil/motor mount, some hardware....and make a harness

[rabies]

got bored waiting on parts made another space science mechanism cover.


new coil and key mount. does not work with dyna coil. use big spacers and mount upsidedown...need longer plug wires :/


new throttle housing. mucho better


new tank and front and rear fenders. and.... plug wires.

[rabies]

nice better fitting wires. sanded edge of coil off to not touch the motor. and enough space to still use the key.


lowbrows said this would fit my bike. it looks like garbage. doesnt line up right. cut weird.

[rabies]

low brows tank was rusted inside - issue.
mini fender. gun bluing experiment.
(before)


dish soap bath. wiped down with alcohol and dipped for a few minutes per instructions.
(after) turned kinda pearly colored. going to try another brand of bluing.

[7and7is]

Watch the oil bag, on the 92 the way the battery tray is mounted to the bag and the weight of the battery tends to crack the tank, my son has a 92 and we had a mystery oil leak, turns out it was the bag and after researching, this is a common problem with this year, we purchased a replacement from lowbrow, fit and finish were on the money, also went with a lithium battery to remove the battery weight from the flawed design.

[rabies]

awesome. thank you sir. i will check it out.
i do have an Antigravity battery on the shelf. im not sure if the old school charging setup will blow out this battery. i had a 77 kz750 with antigravity battery it ballooned the battery. newer bikes they say work better but idk why.

[7and7is]

My 1988 FLHT has an Antigravity battery and Ive had 0 issues, we went with the featherweight lithium battery for my sons 92 because the dimensions were very close to the stock battery, click the link https://www.denniskirk.com/fire-powe...rd/2011123.sku

[rabies]

i will have to give the lithium battery a try. i appreciate it kind sir.

the gun bluing is a bit of a process for big pieces.
torch to heat it up to really soak it in. cant dip them because pieces are too big and solution is so small in volume.
rear fender needs more.
chopped tailight portion off. from lowbrows


low brows frisco tank. came rusted out inside pretty good. customer service told me to pound sand.


1/4" NPT plugs


tank bluing. marbley color. i like it. you may not. i will add more bluing later to get a darker color and preserve the metal.

[DoomBuggy]

Looks like a fun ride! Nice work

[7and7is]

Love the bluing, should just get better as you apply.

[rabies]

Thanx fellas.
Got bike timed i think.
Had faulty ignition switch. Arcing inside.
S&s manifold flange broke causing vacuum leak :/
Was so pumped to ride my bike today.
....ordering parts

[rabies]

used 2 rivnuts for the frisco tank btw.


so...got things together and tried to get it to run.
thought i had wiring right. im sure i do.
thought i had timing right, it fights me with the test light. on all the time.
come to find this broken. vacuum leak.




tac'd it. works find now. plus they are $100 for one..
however the 1/4 junk petcock from lowbrows i dont think feeds enough fuel.
doesnt matter ordered a quality 3/8 from another place.

waiting on new ignition switch. petcock.

[rabies]

cleaning, purple power seems to mess with the aluminum polish surface.
cleaning junk S&S didnt work. im reading theres alot of issues with these...



aluma black. had to sand off the chrome plating. left it like this. kinda neato


made this bras knob thingy.



still wont idle with fuel knob off.

[rabies]

1st attempt to make a sissy bar, 1/2 rebar and map gas.





eh.

[rabies]

rode it to work.
had to adjust float lower 1/4" from the top. carb was over fueling while riding.
cheap chinese rebuild kit for the S&S super e gave me a feed nozzle with an ovaled hole for the float needle (no-go)
strapped battery down properly with its 483lb chrome cover.

ordered 1fngr clutch lever, perch, lane splitter handle bars and seat.